Mailing folder

ABSTRACT

A one-piece foldable corrugated mailer container having a onepiece blank which upon assembly into a box defines locked triangular-like side wall pockets for protecting the side edges during shipment and for holding an object in place away from the peripheral side edges of the folder.

United States Patent [191 McCall Jan. 23 1973 s41 MAILING FOLDER 3,465,946 9/1969 Johnson... ..206/46 FR Inventor: Richard J. McCall, 1515 sedgwick 3,263,897 8/1966 Giroux ..229/40 S Chicago 60610 Primary Examiner.loseph R. Leclair [22] Filed: Sept. 24, 1971 Assistant Examiner-Allan N. Shoap [211 App] 183 460 Attorney-Carlton Hill et al.

. V [57] ABSTRACT E2 ii gg jz A one-piece fol'dable corrugated mailer container having a one-piece blank which upon assembly into a box [58] Fleld Search 87 R206/46 FR defines locked triangular-like side wall pockets for protecting the side edges during shipment and for ['56] Reerences cued holding an object in place away from the peripheral UNITED STATES PATENTS side edges of the folder- 3,426,957 2/1969 McCall....., ..206/46 FR' 7 Claims, 4 Drawing Figures '1 /Z -2"" W n, l g l 42 7 /4 V l l a I 1 I I l 1 H l l l /0 l I 9 a -c: M l fizz 1. .1 .7 7 r I I l c l l 4 I I I. 27 ,7 r22 1 I 24 l l M r h 2/ 23 l 3 M .2 M I 2i MAILING rowan BACKGROUND OF THE INVENTION 1 Field of the Invention This invention relates to one-piece foldable boxes and more particularly to a foldable corrugated mailer container having a one-piece blank characterized by utilization of locked slanted side walls to form protective pockets.

2. Prior Art Mailer containers of various configurations are known. For example my U.S. Pat. Nos. 3,426,957 and 3,550,834 disclose and claim certain improved constructions for shipping of flat and triangular or cylindrical objects respectively. Nevertheless, additional improved configurations are desirable in order to simplify blanks, provide improved pilfer-proof mailer folders, improve the protection afforded to an object being shipped, minimize the complexities of assembly, etc.

SUMMARY OF THE INVENTION Accordingly, the invention provides improved mailer folders having a relatively simple one-piece blank easily assemblable into a container especially suitable for shipment of flat rectangular objects, such as books, having triangular-like side wall pocket construction resisting forces directed against the side edges of such a container. In a preferred embodiment, a perforated strip means is provided along portions of the folder for opening the assembled container which is pilfer-proof sealed by hot adhesives in a manner avoiding protruding end edges.

Many other features, advantages and objects of the invention will become apparent to those versed in the art upon making reference to the detailed description which follows and the accompanying drawings, in which preferred structural embodiments of a mailing folder incorporating the principles of the invention are shown by way of illustrative example, however, variations and modifications may be effected without departing from the spirit and scope of the novel concepts of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a development of a one-piece blank usedto construct an embodiment of the invention:

FIG. 2 is a somewhat reduced partial view illustrating the blank of FIG. 1, with side, rear, top and tucker panels moved into a partially assembled position;

FIG. 3 is a partial elevated perspective view of an assembled folder illustrating one of the triangular-like side wall pockets; and

FIG. 4 is a cross-sectional view taken substantially along the line lVlV of FIG. 3.

DESCRIPTION OF THE PREFERRED EMBODIMENTS The mailer folder or shipping container of the invention is made of a sheet form member, such as a double faced form of corrugated paper blank indicated generally at 10. Such a paper blank has the usual laminar construction consisting of corrugation 35 (best seen at FIG. 3), with the double faces provided by an inside surface sheet and an outside surface sheet joined to the corrugation in a suitable manner. The outside surface sheet may contain any desired indicia-bearing information, such as advertisements, trademarks, etc. The corrugated paper blank is arranged so that the corrugation 35 extend substantially in a transverse direction to the principle extension of blank 10. This disposition of corrugations materially aids the overall strength characteristics of the assembled folder.

In accordance with the principles of the invention, the die cutting process is carried out to afford substantially simultaneous cutting and scoring operations. Thus, blank 10 is simultaneously cut to the pre-selected peripheral configuration along the proper cut lines and also provided with the proper score lines dividing the blank into a plurality of panels disposed in a selected position for assembly of the folder. It will be noted that the four principal score lines are substantially parallel to the direction of the corrugations while the score lines of the side flaps are substantially perpendicular to the direction of the corrugations. This arrangement further contributes to the overall strength characteristics of the novel folder.

Now considering the further details of construction, blank 10 comprises a main body portion having a first score or score line 12 extending generally parallel to the corrugations and thereby defining a first panel in the main body portion, which will be referred to herein as folding tucker wall 11. A second score line 14 is formed in the body portion in spaced relation from score line 12 thereby forming or defining a second panel in the main body portion adjacent the first panel and hingedly integrated therewith. This second panel will be referred to hereinafter as front wall 13. It is to be understood that the terms front, rear, top, bottom, etc. are used throughout the specification of the invention only for purposes of illustration and reference, and that the relative positions of these panels can be interchanged without the departing from the basic inventive concepts.

The body portion of the blank sheet form member 10 is provided with a further score line 16, which is spaced in parallel relation from score line 14 so as to form a third panel adjacent and hingedly integrated with the front walll3. The third panel will be referred to herein as top wall 15. A score line 18 is spaced from the score line 16 a distance approximately equal to the longitudinal dimension (i.e. height) of front wall 13 and forms a fourth panel adjacent the top wall. This fourth panel, which will be referred to herein as rear wall 17, is hingedly integrated with the top wall 15. A pair of opposed imperforated recesses 19 and 19a are provided along the side edge portions of rear wall 17. The recesses 19 and 19a are somewhat U-shaped, rotated from vertical, having one leg or boundary thereof laying substantially along score line 16 between the top and rear wall. Each of the recesses 19 and 19a open toward each other and toward the center of rear wall 17. The recesses 19 and 19a are preferably cut only through one of the face sheets of blank 10 and the corrugations within the cut area are somewhat compressed so as to readily receive a mating member and hold it in place.

The remaining portion of blank 10 comprises a fifth panel which will be referred to herein as bottom wall 21. The side portions of bottom wall 21 are provided with a first pair of longitudinal score lines 22 and 23 respectively, that extend generally transversely to the direction of the corrugations thereby forming an integral hinge connection between the respective twopanel flap portions and the bottom wall 21. A second pair of longitudinal score lines 26 and 27 respectively are provided in spaced parallel relation to score lines 22 and 23 respectively so as to form side walls 24 and 25 and flange walls 28 and 29.. In assembly, side walls 24 and 25 assume a slanted position and function as reinforcement means for resisting forces against side edges of the folder while the flange walls 28 and 29 function as locking means therefore and maintain the slanted side wall and an object within the folder in proper relation to each other. The inner side edges of flanges 28 and 29 respectively (in the vicinity of the real wall) project beyond the corresponding side wall edges as somewhat triangular-shaped ear-like members 32 and 32a. The ear-like members 32 and 32a extend from the outer side edges of flanges 28 and 29 toward the center of blank a distance that is approximately equal to the distance that the imperforated recesses 19 and 19a extend inwardly from the outer edges of rear wall 17. In assembly, the ear-like members 32 and 32a mate or lock with recesses 19 and 19a respectively and are maintained in position as best seen in FIG. 2.

The spacing dimension between score lines 22, 26 and 23, 27 must be at least equal to the spacing between score lines 12, 14 and 16, 18. Preferably, the spacing between score lines 22, 26 and 23, 27 is somewhat larger than the spacing between score lines 12, 14 and l6, 18 so as to provide for the formation of slanted side walls in the assembled folder that form angles with the top and bottom wall of less than about 90 and preferably about 45.

A perforated tear-strip is provided along a portion of blank 10 to facilitate opening of the assembled and sealed folder. In the embodiment illustrated at FIG. 1, tear-strip 33 extends from about score line 11 downwardly across the top and rear walls 15 and 17 respectively and terminates in a lift-tab 33a positioned in the lower portion of the bottom wall 21. Other arrangements of this or similar means for opening a sealed container are also included within the scope of the invention.

In assembling the mailer folder, substantially as illustrated in FIGS. 2 and 3, the two-panel side flap portions 24, 28 and 25, 29 are first folded upwardly along score lines 22 and 23 respectively into a substantially perpendicular position in the respect to the bottom wall 21. Then the flange walls 28 and 29 are folded inwardly to substantially perpendicular positions in respect to side walls 24 and 25 and substantially parallel but spaced relation to bottom wall 21.

Next, the rear wall 17, simultaneously with the top wall 15, is folded upwardly along score line 18 to a substantially perpendicular position in respect to bottom wall 21. The side wall 24 and 25 are then moved so as to form an angle, say of about 45, with the bottom wall 21 and the ear-like members 32 and 32a are inserted into the imperforated recesses 19 and 19a respectively. Then the top wall 15 is folded downwardly (having been folded upwardly simultaneously with the rear wall 17) until the outer faces of the flange walls 28 and 29 contact the inner face of the top walls. Thereafter the folding tucker wall 1 1 is folded along score line 12 so as to form an angle with front wall 13, causing the outer edges of the tucker wall to move into the now-formed folder. Substantially simultaneously, the front wall 13 is folded upwardly along score line 14 forcing the tucker wall 11 into the interior of the formed chamber. It will be noted that the interior configuration of the assembled folder is substantially of trapezoidal configuration, while the exterior is substantially of rectangular configuration.

In the embodiment illustrated at FIG. 1, the outer corner edges 11a of the tucker wall 11 are substantially square. In the embodiment shown in FIG. 2, the outer corner edges 11b of the tucker wall 11 are rounded. Both embodiments are within the scope of the invention and in certain embodiments, the rounded corner configuration provides for easier assembly of the folder. The folder is preferably sealed during assembly by a hot milling glue process whereby hot glue or adhesive is applied at least along face of the tucker wall 1 1. If desired, hot glue may also be applied between the flange walls 28, 29 and contiguous top wall surfaces, however, the interlocking relation between the ear-like members 32, 32a and imperforated recesses 19, 19a is sufficient to prevent the sides of the assembled folder from being accidentally or deliberately opened. Hot glue sealing, along with the inward positioning of all edges renders the assembled folder substantially pilferproof since it is necessary to destroy the folder, as by the use of the tear-strip 33 to obtain access to the interior thereof.

As best seen in FIG. 3, when the sequentially assembled process is completed, there are substantially identical triangular-like side wall pockets formed on both side edges of the assembled folder. The triangular like side wall pocket seen at FIG. 3 is defined by the extending edge portions 17a of rear wall 17, the extending edge portions 15a of top wall 15 and the slanted side wall 24. A similar side wall pocket is formed on the opposite side of the folder defined by corresponding portions of the blank.

The triangular-like side wall pockets provided by the novel configurations forming the mailing folders of the invention provide exceptional protection to the interior edges of objects such as books, within the container. The inner most portion 24a of the slant side wall 24 holds the edges of an object within the folder away from the side edges thereof so that any force or the like directed against the side edges is absorbed by the material forming the side wall pocket. Forces directed at an angle to the side edges of the folder are dissipated by the slanted side walls, which are locked in position. Should the external forces overcome the resistance of the material forming the side wall pockets and crush portions thereof, the object within the folder is still fairly protected by the inward spacing thereof from the damaged side edges by the inner most portion 24a of the slanted side wall 24.

The triangular-like side wall pockets thus provide exceptional safety for the contents of the box-like mailer folder constructed in accordance with the principles of the invention and allow relatively negligent or rough handling without concern for content damage. This type of construction is especially useful as a mailer folder for flat objects, such as books or other similar objects needing edge protection so that such objects can be shipped with assurances that the books, etc. will arrive in their original condition. The extending edge portions of the various panels defining the side wall pockets are so-aligned that the corrugation of the blank are disposed in parallel relation to the plane of the top and bottom walls and present a substantially perpendicular or end-grain configuration to any outside objects or foroesbr'ought against the side edges of the mailer folder. Thus, the corrugations present substantially rigid reinforced end portions that are not easily bendableor otherwise damaged. The triangular-like configuration of the side wall pockets allows complete protection of the end edges of flat objects with a minimum amount of stock and provide a relatively easily attained configuration.

FIG. 4 is substantially a cross-sectional view taken along lines IV-lV of FIG. 3 illustrating certain details of the locking relation between an ear-like member 32 and an imperforated recess 19. Rear wall 17 is cut in a tilted, U-shaped imperforated recess 19 along its inner face 17b and the corrugations within the imperforated recess 19 are somewhat compressed so as to form a receiving area thereat. The projecting ear-like member 32 fits within this recess and is prevented from withdrawal by the remaining material of inner face 17b. The resulting slanted side wall 24 holds an object within the folder away from the exterior edges portions thereof and resist forces directed against the edges of the folder. v I

Although minor modific'ations may be apparent to those skilled in theart from the foregoing details relating to exemplary embodiments, it should be understood that I wish to embody within the scope of the patent I warranted hereon all such modifications as reasonably and properly come within the scope and spirit of my contribution to the art;

I claim as my invention:

' l. A mailer folder comprising a one-piece blank scored, stripped and cut along substantially perpendicular lines to form a bottom, rear, top, and front wall with a folding tucker member and opposing two-panel flap members hingeably integrated with said bottom wall forming respective sidewalls, said rear wallhaving opposing imperforated recesses along the boundary between said rear wall and top'wall, said two-panel flap members each comprising a side wall hingeably integrated with the bottom wall and a lflange wall hingeably integrated with said side wall, said flange wall having a projectionextending from a side edge thereof in the vicinity of said rear wall and adapted for mating with said imperforated recess therein, said bottom,

rear, top, front, side, flange wall and folding tucker member being sequentially foldable along said perpendicularlines to form a substantially rectangular exterior folder having asomewhat trapezoidal interior chamber,

saidfolding tucker being foldable into said interior chamber, said side walls being held at an angle to the top and bottom walls by said projection of the flange wall in registry with the imperforated recesses-so as to define opposing triangular-like side wall pockets outand bottom walls.

3. A mailer folder as defined in claim 1 including a perforated tear-strip extending along the blank from about the front wall through the top and rear walls and for a distance on the bottom wall to, facilitate opening of the assembled folder.

4. A mailer folder as defined in claim 1 wherein at least a folding tucker member is provided with hot glue for sealing the assembled folder in a substantially pilferproof manner.

5. A mailer folder comprising a one-piece blank scored, stripped, and cut to form a five-panel section forming bottom, rear, top, front and folding tucker walls having relatively perpendicular edges, with the folding tucker wall being foldable in a first direction, a pair of two-panel side flap members hingedbly integrated with said bottom wall and being foldable generally perpendicular to said first direction, said rear wall having a pair of imperforated recesses in the vicinity of the side edges thereof opening toward each other,

said imperforated recesses having a boundary thereof said bottom wall, said flange walls eachhaving a side edge in the vicinity of said rear wall projecting beyond a corresponding side wall edge and adapted for mating with said imperforated recesses, said rear wall being sequentially foldable into a substantially perpendicular relation to said bottom wall and said flange wall so that the flange side edge protruding beyond the corresponding side wall edge locks with said imperforated recess, said top wall being sequentially foldable into a substantially spaced parallel relation to said bottom wall and into contact with said flange walls, said top and rear walls defining substantially triangular extending edge portions along sides of the assembled folder, saidfolding tucker wall being sequentially foldable into substantially planar relation with the top and bottom wall, and a pair of opposed outwardly opening triangular-like side wall pockets extending beyond said slanted side walls for resisting outside forces directed against the sides of the assembled folder.

6. A mail folder as'defined in claim 5 wherein the folding tucker wall is provided with rounded corners at the outer extremities thereof for ease of assembly.

7. A mailer folder as defined in claim 5 further characterized by being formed of corrugated stock and having the corrugations thereof extending transversely relatively to the principal extension of the blank from which said folder is formed.

i I I l i 

1. A mailer folder comprising a onE-piece blank scored, stripped and cut along substantially perpendicular lines to form a bottom, rear, top, and front wall with a folding tucker member and opposing two-panel flap members hingeably integrated with said bottom wall forming respective side walls, said rear wall having opposing imperforated recesses along the boundary between said rear wall and top wall, said two-panel flap members each comprising a side wall hingeably integrated with the bottom wall and a flange wall hingeably integrated with said side wall, said flange wall having a projection extending from a side edge thereof in the vicinity of said rear wall and adapted for mating with said imperforated recess therein, said bottom, rear, top, front, side, flange wall and folding tucker member being sequentially foldable along said perpendicular lines to form a substantially rectangular exterior folder having a somewhat trapezoidal interior chamber, said folding tucker being foldable into said interior chamber, said side walls being held at an angle to the top and bottom walls by said projection of the flange wall in registry with the imperforated recesses so as to define opposing triangular-like side wall pockets outside said interior chamber when the folder is in assembled position thereby holding objects within the chamber away from the exterior edges of said folder and protecting end edges thereof from outside forces.
 2. A mailer folder as defined in claim 1 wherein the side walls are held at an angle of about 45* to the top and bottom walls.
 3. A mailer folder as defined in claim 1 including a perforated tear-strip extending along the blank from about the front wall through the top and rear walls and for a distance on the bottom wall to facilitate opening of the assembled folder.
 4. A mailer folder as defined in claim 1 wherein at least a folding tucker member is provided with hot glue for sealing the assembled folder in a substantially pilfer-proof manner.
 5. A mailer folder comprising a one-piece blank scored, stripped, and cut to form a five-panel section forming bottom, rear, top, front and folding tucker walls having relatively perpendicular edges, with the folding tucker wall being foldable in a first direction, a pair of two-panel side flap members hingedbly integrated with said bottom wall and being foldable generally perpendicular to said first direction, said rear wall having a pair of imperforated recesses in the vicinity of the side edges thereof opening toward each other, said imperforated recesses having a boundary thereof substantially along the score between said rear and top walls, said two-panel side flap members being sequentially foldable into opposed slanted side walls forming an angle of less than 90* with said bottom wall and into flange walls foldable in generally parallel relation to said bottom wall, said flange walls each having a side edge in the vicinity of said rear wall projecting beyond a corresponding side wall edge and adapted for mating with said imperforated recesses, said rear wall being sequentially foldable into a substantially perpendicular relation to said bottom wall and said flange wall so that the flange side edge protruding beyond the corresponding side wall edge locks with said imperforated recess, said top wall being sequentially foldable into a substantially spaced parallel relation to said bottom wall and into contact with said flange walls, said top and rear walls defining substantially triangular extending edge portions along sides of the assembled folder, said folding tucker wall being sequentially foldable into substantially planar relation with the top and bottom wall, and a pair of opposed outwardly opening triangular-like side wall pockets extending beyond said slanted side walls for resisting outside forces directed against the sides of the assembled folder.
 6. A mail folder as defined in claim 5 wherein the folding tucker wall is provided with rounded corners at the outer extremities thereof for ease of assembly.
 7. A mailer folder as defined in claim 5 further characterized by being formed of corrugated stock and having the corrugations thereof extending transversely relatively to the principal extension of the blank from which said folder is formed. 